Inflatable game ball and method for manufacturing the same

ABSTRACT

An inflatable game ball includes an inflatable bladder, a winding layer surrounding the bladder, a rubber inner carcass layer surrounding the winding layer, and a cellular outer carcass layer surrounding the inner carcass layer. During manufacture of the game ball, the bladder is first inflated. A plurality of yarns are wound around the inflated bladder to form the winding layer, on which the inner carcass layer is molded. A plurality of patches are interconnected by stitching to form a bag that has an opening. The bag is reversed, and the bladder is deflated so that an assembly of the bladder, the winding layer, and the inner carcass layer can be inserted into the reversed bag via the opening. The opening in the bag is then closed by stitching so as to form the outer carcass layer on the inner carcass layer.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates to an inflatable game ball, such as basketball, football, soccer ball, and volleyball, and the method for making the same, and more particularly to an inflatable game ball, which includes a rubber inner carcass layer that is disposed between a winding layer and an outer carcass layer.

[0003] 2. Description of the Related Art

[0004] Referring to FIGS. 1 and 2, a conventional inflatable game ball in the form of a soccer ball is shown to include an inflatable bladder 21 with an air valve 22, a winding layer 23, and a cellular outer carcass layer 24. FIG. 2 is a flow diagram that illustrates a process for manufacturing the conventional inflatable game ball, which includes the following steps:

[0005] inflating the bladder 21;

[0006] winding a plurality of yarns 231 around the bladder 21, and subsequently coating the yarns 231 with glue 232 so as to form the winding layer 23, with the air valve 21 extending through and being exposed outward from the winding layer 23;

[0007] interconnecting a plurality of patches 241 by stitching along outer peripheries 242 (see FIGS. 2 and 2A) thereof so as to form a bag 24′ that has an opening 243, one of the patches 241 having a hole 244 formed therethrough;

[0008] reversing the bag 24′ so as to conceal the stitched outer peripheries 242 of the patches 241 within the bag 24′;

[0009] deflating the bladder 21 and inserting the assembly of the bladder 21 and the winding layer 23 into the bag 24′ via the opening 243, with the air valve 22 extending into the hole 244 and being exposed outward from the bag 24′;

[0010] closing the opening 243 of the bag 24 by stitching so as to form the outer carcass layer 24 on the winding layer 23; and

[0011] inflating the bladder 21.

[0012] The aforesaid conventional game ball suffers from a drawback in that because seamed portions 245 of the outer carcass layer 24 have different impact-resistant strengths due to different stitch numbers per unit length of seam, when the game ball is subjected to an impact, air will flow within the bladder 21 toward the weaker seamed portions 245 of the outer carcass layer 24, thereby resulting in deformation of the game ball after long-term use.

SUMMARY OF THE INVENTION

[0013] The object of this invention is to provide an inflatable game ball, which includes a rubber inner carcass layer that is disposed between an outer carcass layer and a winding layer so as to offer an impact-absorbing resilience when the game ball is subjected to an impact and so as to help maintain a fixed shape of an inflatable bladder when no impact is applied on the game ball, thereby avoiding the deformation of the game ball.

[0014] According to this invention, an inflatable game ball includes an inflatable bladder, a winding layer surrounding the bladder, a rubber inner carcass layer surrounding the winding layer, and a cellular outer carcass layer surrounding the inner carcass layer. During manufacture of the game ball, the bladder is first inflated. A plurality of yarns are wound around the inflated bladder to form the winding layer, on which the inner carcass layer is molded. A plurality of patches are interconnected by stitching to form a bag that has an opening. The bag is reversed, and the bladder is deflated so that an assembly of the bladder, the winding layer, and the inner carcass layer can be inserted into the reversed bag via the opening. The opening in the bag is then closed by stitching so as to form the outer carcass layer on the inner carcass layer.

[0015] Because the inner carcass layer is made of rubber, it can offer an impact-absorbing resilience, thereby reducing air flow within the bladder when the game ball is subjected to an impact.

[0016] Furthermore, because the bladder and the winding layer are disposed within the rubber inner carcass layer, a fixed shape of the bladder can be maintained when no impact is applied on the game ball.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features and advantages of this invention will become apparent in the following detailed description of a preferred embodiment of this invention, with reference to the accompanying drawings, in which:

[0018]FIG. 1 is a fragmentary sectional view of a conventional inflatable game ball;

[0019]FIG. 2 is a flow diagram illustrating a process for manufacturing the conventional inflatable game ball;

[0020]FIG. 2A is a schematic view illustrating the connection between two patches of the conventional inflatable game ball;

[0021]FIG. 3 is a fragmentary sectional view of the preferred embodiment of an inflatable game ball according to this invention, illustrating arrangement of an inflatable bladder, a winding layer, a rubber inner carcass layer, and a cellular outer carcass layer;

[0022]FIG. 4 is a partly sectional view of the preferred embodiment when deflated;

[0023]FIG. 5 is a flow diagram illustrating a process for forming the winding layer and the inner carcass layer on the bladder;

[0024]FIG. 6 is a flow diagram illustrating how the outer carcass layer is formed from a plurality of patches;

[0025]FIG. 6A is a schematic view illustrating the connection between an adjacent pair of the patches; and

[0026]FIG. 7 is a flow diagram illustrating a process for assembling the outer carcass layer on the inner carcass layer.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0027] Referring to FIGS. 3 and 4, the preferred embodiment of an inflatable game ball 1 according to this invention is shown to include an inflatable bladder 11 with an air valve 12, a winding layer 13 surrounding the bladder 11, a rubber inner carcass layer 14 surrounding the winding layer 13, and a cellular outer carcass layer 15 surrounding the inner carcass layer 14. The outer carcass layer 15 includes a plurality of patches 151, each adjacent pair of which are fastened to each other by stitching along outer peripheries 154 (see FIGS. 6 and 6A) thereof. The air valve 12 extends through a hole 133 in the winding layer 13, and two holes 141, 152 in the inner and outer carcass layers 14, 15, and is exposed outward from the outer carcass layer 15 to permit inflation of the bladder 11. The inner carcass layer 14 may be made of natural rubber or synthetic rubber.

[0028] A method for manufacturing the game ball 1 includes the following steps:

[0029] blowing air into the air valve 12 so as to inflate the bladder 11, as shown in FIG. 5;

[0030] winding a plurality of yarns 131 around the inflated bladder 11, and subsequently coating the yarns 131 with glue 132 in a known manner so as to form the winding layer 13 that surrounds the bladder 11, with the air valve 12 extending through the hole 133 in the winding layer 13 and being exposed outward from the winding layer 13, as shown in FIG. 5;

[0031] molding the inner carcass layer 14 that surrounds the winding layer 13, with the air valve 12 extending through the hole 141 in the inner carcass layer 14 and being exposed outward from the inner carcass layer 14, as shown in FIG. 5;

[0032] interconnecting the patches 151 by stitching along the outer peripheries 154 thereof in a known manner so as to form a bag 15′ that has an opening 153, as shown in FIGS. 6 and 6A;

[0033] reversing the bag 15′ so as to conceal the stitched outer peripheries 154 (see FIGS. 6 and 6A) of the patches 151 within the bag 15′, as shown in FIG. 6;

[0034] deflating the bladder 11 and inserting an assembly of the bladder 11, the winding layer 13, and the inner carcass layer 14 into the reversed bag 15′ via the opening 153, with the air valve 12 extending into the hole 152, as shown in FIG. 7;

[0035] closing the opening 153 in the bag 15′ by stitching so as to form the outer carcass layer 15 on the inner carcass layer 14; and

[0036] inflating the bladder 11.

[0037] Because the inner carcass layer 14 is made of rubber, when the game ball 1 is subjected to an impact, the inner carcass layer 14 can offer an impact-absorbing resilience, thereby enhancing durability of the game ball 1. Furthermore, because the bladder 11 and the winding layer 13 are disposed within the inner carcass layer 14, when no impact is applied on the game ball 1, the inner carcass layer 14 can help maintain a fixed shape of the bladder 11.

[0038] With this invention thus explained, it is apparent that numerous modifications and variations can be made without departing from the scope and spirit of this invention. It is therefore intended that this invention be limited only as indicated by the appended claims. 

I claim:
 1. An inflatable game ball comprising: an inflatable bladder with an air valve; a winding layer surrounding said bladder; a rubber inner carcass layer surrounding said winding layer; and a cellular outer carcass layer surrounding said inner carcass layer and including a plurality of patches, each adjacent pair of which are fastened to each other by stitching along outer peripheries thereof, said air valve extending through said winding layer and said inner and outer carcass layers, and being exposed outward from said outer carcass layer to permit inflation of said bladder.
 2. The inflatable game ball as claimed in claim 1, wherein said inner carcass layer is made of natural rubber.
 3. The inflatable game ball as claimed in claim 1, wherein said inner carcass layer is made of synthetic rubber.
 4. A method for manufacturing an inflatable game ball, the method comprising the steps of: blowing air into an air valve on an inflatable bladder so as to inflate said bladder; winding a plurality of yarns around said bladder, and subsequently coating said yarns with glue so as to form a winding layer that surrounds said bladder, with said air valve extending through and being exposed outward from said winding layer; molding a rubber inner carcass layer that surrounds said winding layer, with said air valve extending through and being exposed outward from said inner carcass layer; interconnecting a plurality of patches by stitching along outer peripheries thereof so as to form a bag that has an opening, one of said patches having a hole formed therethrough; reversing said bag so as to conceal the stitched outer peripheries of said patches within said bag; deflating said bladder and inserting an assembly of said bladder, said winding layer, and said inner carcass layer into said bag via said opening, with said air valve extending into said hole; and closing said opening in said bag by stitching so as to form an outer carcass layer on said inner carcass layer. 